Process of making artificial stone wall facings



Oct, l2, 1937. L A. KNIGHT PROCESS 0F MAKING ARTIFICIAL STONE 'WALLFACINGS Filed hay 17, 1.9 57

Patented ocr. 12, 1937 UNITED STATES PATENT clsica PROCES-S F MAKINGARTIFICIAL WALL FACINGS Application May 17, 1937, serial No. 143,199

11 Claims.

This invention relates to artiflcial stone wall facings and finishes andprocess of making same and has particular reference to polychrome wallfacings and finishes of this character.

There has been a long felt need in this art for wall facings, adaptedfor use on base structures of wood, metal, brick, cement, concreteblock, `cinder block, stone, etc. that will resemble as much as possiblethe natural stone facings and finishes and also possess to as great orgreater extent the durability and wearing qualities 'of natural stonefacings.

' Many attempts to solve this problem have heretofore been attempted butthe results have been attended by distinctive disadvantages.

In one of these prior processes, plastic material is applied to a wallfrom specially designed molds. Each mold is provided with a plungerwhereby the material is forced out of the mold and pressed against thewall. The surface of the plunger is corrugated or crinkled to producethe corresponding design on the finished surface. Before filling themold with the plastic material the face of the plunger is covered withwaxed paper to prevent adhesion of the plastic material to the plunger.For each different design and size of stone to be formed on the wall adifferent mold must be used, thus involving considerable cost andnecessitating a. large stock of molds to produce the desired variety ofarticial stone facings. To provide the proper chromaticeffects, pigmentsof the desired shade and color are sprinkled on the waxed paper withinthe mold before the plastic material is poured in.. vThis results in 35an extremely supercial tinting of the facing. which readily wears awayor becomes discolored e through the action of the atmospheric elements.

A still further disadvantage of this prior process is that whenartificial stone facings of large 4 area are to be formed on the walls,the mold and the contents `of plastic material assume great weight andthe process becomes laborious. Pressure must also be exertedy in theapplication of the material to the walls, thus adding further to thelabors of the operation. It has also been found that, in the finalconstruction, contact between the facing andthe wall cannot be assuredfor the entire extent of the wall treated, and there is also muchuncertainty as to the location and extent of any contact that isproduced. As a consequence, objectionable airpockets of undesirableextent exist in the final structure, resulting in a great weakening ofthe bond between wall and facing and rendering the wall facing very sus-STONE (Cl. 'I2-17) ceptible to easy destruction through breaking,

scaling or chipping.

A still further objection to this process is that it requires speciallytrained labor to produce a finished piece of work of satisfactory andproper appearance.- The tools employed for this process and the mode ofoperation are entirely foreign to the very simple tools and the mode ofoperation of masons and cement finishers, which necessitates thetraining ofspecially skilled labor.' 'Ihe 'proper positioning of each ofthe masses of plastic material forced 'from the mold onto the wall toeffect proper alinement with each other of the individual sections ofvarying size and shape requiresl much skill and practice and thereforeinvolves additional items of expense. v Also, the plunger does notreadily separate from the mass of plastic material after its applicationto the wall and it isdiiiicult to prevent disturbance of the plasticmaterial on the wall during such removal of the plunger. Suchdisturbance results in marring the outward configuration of the facingand also produces checks, cracks and fissures in the plastic material,all of which weaken and mar the final wall facing. lAmong the objects ofthis invention is to provide a Wall facing that will be free from theobjections heretofore described to the wall facings produced by theparticular prior process outlined heretofore, and to provide a processwhereby the objections anddisadvantages of the prior process heretoforeset forth are eliminated.

A further object of this invention is to provide a process for making anartificial stone facing that may be readily carried out by masons andcement finishers and wherein the tools used by masons and cementfinishers are utilized.

`A still further object of this invention is to provide a processformaking an artificial stone facing which can be employed for walls ofvarious design and construction, including rounded structures as well asstraight faced walls. 4

Other, further and more specific objects of this invention will becomereadily apparent to persons skilled in the art from a consideration ofthe following description when taken in conjunction with theaccompanying drawing where- 1n:

Figs. 1 and 2 are fragmentary perspective views showing several layersof coating material applied to walls of Wood, and masonry. In Fig. l,the facings are shown in unnished form. In Fig. 2, the facing duringthree stages of the process' is shown.

Fig. 3 is a fragmental cross-section through a -metal and preferably 2wall showing the several layers of plastic material applied to a wall.

Fig. 4 is a side view of a specially designed roller with crinkledsurface used in my process.

Fig. 5 is a perspective view of the chasing tool used in my process.Fig. 6 is a side view of the fiat-faced edging roller used in myprocess.

Upon a wall 2 of wood, a lath 4 of wood or reticulated or perforated isattached to the wall. A layer 8 of plastic material, such as cementmortar, is applied over the lath and the surface of this layer is scoredbefore it sets and dries. The lath 4 serves to re-inforce the layer 6and aid its adherence to the wall 2. After the layer 6 dries, anotherlayer of plastic material 8 is applied thereon, and promptly score-linedaccording to the pre-determined position, spacing, conguration and sizeof the stone desired.

Upon this second layer 8, the outer layer I8 of plastic material is'formed by applying mortar cements of the particular color or shadedesired upon the respective zones or areas formed by score-lining thesurface of the layer 82 The plastic material or mortar cement of theouter layer II) is preferably of two or. more colors and/or shades uponeach area or zone, but very satisfactory results may be obtained undercertain conditions with mortar of a single distinctive color upon one ormore of these zones or areas. The layers of plastic material 6, 8 and I8are applied with a trowel. The layer'B is preferably from to inchthick.. The layers 8 and I8 are preferably from 1/4 to inch thick.

Where the base or wall is of masonry no metal or other lath is needed,the rst coating 8 being applied directly to the masonry I2, and theother coatings 8 and I0 are applied as heretofore described for woodenbases or walls.

Upon the layer I0 of variously colored mortar cement, .while such cementis in the plastic condition, crushed stone or granules, or variouslycolored powdered materials such as mica, oxide pigments, stone dust,slate dust, chips of mineral or artificial stone, diatomaceous earth,kieselguhr, volcanic scoria, etc., are dashed on by hand or with airpressure to produce the desired speckled surfaces in simulationofspecial natural rocks or stones.

After application of this comminuted material to the surface I8, andbefore the cement in the layer I0 has become set, waxed paper I4 orother lamina which does not adhere to the plastic material is spreadthereon, after which the roller I6 having the crinkled surface I1 ispassed over the waxed paper in the directions desired and withsufficient pressure to produce the crinkled surface on the outer layeror facing I0. After the roller has passed over the waxed paper appliedto the plastic coating I0, there will be formed on this coatingelevations I8 and depressions 20 corresponding to the part of the roller-in contact with the facing during the rolling process and resemblingthe variegated crinkled surfaces of undressed stone.

The waxed paper is then removed and, while the coating I8 is still inplastic condition, the crinkled surface is scored with the chasing tool22, substantially` following the score-lines previously formed on thelayer v8. The chasing tool 22 has two parallel cutting edges 24 and isused to form the grooves or furrows 26 in simulation of the mortarjoints in natural stone structures and thereby producing, in thefinishing coating I0, blocks of various stone-like sizes. The distancebetween the cutting edge 24 of the tool 22 is equal to the width of theordinary mortar Joints. p

I have found furrow or groove 28 of a depth approximating the thicknessof the finishing coating I0, in which case the outer layer I0 isgouged-until the layer 8 is exposed at these grooves.

A flat-faced edging roller 28 is' the'n run in these grooves 26 aroundthe outside edge of each of the fashioned blocks, the roller pressingthe it very satisfactory to have this edge down to simulate a hammeredrock of rough,

rugged edge. The grooves 26 may also be formed smooth instead of with arough, rugged edge.

If desired, the grooves 28 may be filled with mortar 30 of any desiredcolor or shade. This material may be formed with a bead 32, as shown inFig. 3, or fashioned into any other form.

After the nishing surface has been allowed to v take an initial set, itis brushed vigorously'with a stiff bre'brush thereby removingcementitious lm and exposing the variously colored materials andgranules which were blasted upon or otherwise applied to the surface.

'Ihe facings produced by my novel process possess a very attractiveappearance, eifectively simulating that of unfinished or undressednatural stone. Since the mortar c'ements used for yielding the'polychrome effects have the pigment incorporated throughou't the massesand since these f colored mortar cements are of substantial depth,

the color extends a substantial distance belowv the surface of thefacing.

In addition to the variegated crinkled surfaces produced on the facing,the roller I6 also blends the .cementitious materials of differentcolors and thereby enhances the appearance of the facings.

The plastic mortar cement may be made of various kinds of cementitiousmixtures, such as Portland cement, hydraulic cement, quick or slowsetting cements, plaster, etc., with ground or crushed rock and sand.

The roller for producing the crinkled surface on the facing ispreferably made of cast aluminum. If desired, several rollers ofdifferent contours and/o1` different sizes may be employed to admit theproduction of a greater variety of designs on the crinkled surfaceblocks or sections and also to permit operation in corners of walls andother restricted zones. My process is adapted for use on curved andother irregular base structures as well as fiat bases or walls, and inthis respect possesses a very valuable advance over the prior processeswhich have been found very dimcult to operate on anything other than atwalls.

In analternative procedure, after forming the crinkled surface on vtheouter coating I0 and while this coating I0 is in plastic condition, the

,waxed paper is cut through where the furrows or grooves are to beformed, the coating then gouged to the desired depth to form the furrowsor grooves, and the waxed paper later removed from the blocks ofVartificial stone.

tendency of these colors to fade, and enhance the appearance of thefacing.

A still further modification of this invention is to apply to the facingI0 fragments of iron', copper, brass or bronze, before the crinklingstep of the process. These metals on rusting or corroding by theatmosphere produce unique colorations.

The advantages of my process over themethod heretofore employed are asfollows:

1. The need for a large number of molds, heretofore employed to simulatethe various surface irregularities of natural undressed stone, isovercome.

2. A much greater area of surfacing can be accomplished with a givenamount of labor in a given amount of time.

3. A firmer and better bond between the several coatings andparticularly between the second coating and the outer coating isobtained .with the troweling operations of my process than in the priorprocess where there is either poor contact or no contact at all overextensive areas between the outer facing and itsisupport.

4. By my process there is assured a suicient depth of colored materialso that it will withstand, for long periods of time, erosion and otherwear of the atmosphericl elements without losing its characteristiccolorations and appearance.

5. With my process there is no need for using pressure when applying theouter surface. Merely smearing the plastic material with a trowel hasbeen found satisfactory and' there is formed a surface that iscontinuous and free from cracks, breaks and other undesirable voidsincident to prior constructions of this type.

Thisl application is a continuation-in-part of my application Ser. No.128,504, filed March 1, 1937.

The present invention is not limited to the specic details set forth inthe foregoing examples which should be' construed as illustrative andnot by way of limitation, and in view of the numerousmodiflcationswhichmay be effected therein without departing from lthe spirit and scope ofthis invention it is desired that only such limitations be imposed asareindicated in the appended claims.

I claim as my invention:

1. In a process of making an artificial stone facing, applying to asupporting base a layer of cementitious material in plastic form,marking the surface of said'layer into zones in simulation of individualstones in facings of natural stone, then applying upon said layercolored cementitious material in plastic form at said zones, coveringsaid colored cementitious material with a.

lamina of material to which the plastic material does not adhere,passing a tool over said lamina and producing in the outer plasticcementitious materials elevations andvdepressions resembling those ofundressed stone, removing the non-adhering lamina, and then forming insaid outer plastic cementitious material furrows or grooves of designand configuration substantially in alinement with the priorI markings onthe surface of said first layer of cementitious material and insimulation of mortar joints on the surfaces of stone structures.

2. In a process of making an artificial stone facing, applying to asupporting base a layer of cementitious material in plastic form,marking the surface of said layer into rones in simulation of individualstones in facings of natural stone, then applying upon said layer othercementitious material in plastic form and of a plurality of colors atsaid zones, dashing colored, comminuted material upon the outer plasticmaterial, covering the latter with thin waterproof paper, passing aroller with a crinkled surface over said paper and producing in theouterplastic cementitious materials elevations and depressions resemblingthose of undressed stone, removing the waterproof paper, and `thenforming in said outer plastic cementitious material furrows or groovesof design and configuration substantially in'alinement with the priormarkings on the surface of said first layer of cementitious material andin simulation of mortar joints on the surfaces of stone structures.

3. In a process of making an artificial stone facing, applying to asupporting base a layer of cementitious material in plastic form,score-lining the surface of said layer into zones in simulation ofindividual stones in facings of natural stone, then troweling said layerwith colored cementitious material in plastic form at said zones,covering said colored cementitious material with a lamina of material towhich the plastic material does not adhere, passing a roller with acrinkled surface over said lamina and producing in the outer plasticcementitious materials elevations and depressions resembling those ofundressed stone, removing the non-adhering lamina, and then forming insaid outer plastic cementitious material furrows or grooves of designand configuration substantially in alinement with the priorscore-linings on the surface of said rst layer of cementitious materialand in simulation of mortar joints on the surfaces of stone structures.l

4. In a process of making an artificial stone facing, applying to 'asupporting base a layer of cementitious material, in plastic form,scoring the surface of said cementitious material and allowing same toset and dry, applying thereon another'layer of cementitious material inplastic form, marking the surface of the second layer into zones insimulation of individual stones in facings of natural stone, thenapplying upon said second layer colored cementitious material in plasticform at said zones, covering said colored cementitious material with alamina lof material` to which the plastic materialdoes not adhere,passing a tool over said lamina and producing in the outer plasticcementitious materials elevations and depressions resembling those ofundressed stone, removing the non-adhering lamina, and then forming insaid outer plastic cementitious material furrows or grooves of designand configuration substantially in alinement with the prior markings onthe surface ot' the second layer of cementitious material and insimulation of mortar joints on the surfaces of stone structures.

` corrodible in the atmosphere, covering the outer plastic material witha lamina of material to which the plastic material does not adhere,passing a tool over said lamina and producing in the outer plasticcementitious materials elevations and 4depressions resembling those ofundressed stone, removing the non-adhering lamina, and

then forming in said cuter plastic cementitious materials furrows orgrooves of design and configuration substantially in alinement with theprior markings on the surface of said first layer of cementitlousmaterial and in simulation of mortar joints on the surfaces of stonestructures.

6. In a process of making an artificial stone facing, applying tofasupporting base a layer of material in plastic form, marking the surfaceof said layer into zones in simulation of individual stones in facingsof natural stone, then applying upon said layer colored cementitiousmaterial in plastic form at said zones,

then applying other material which reacts chemically with the outercementitlous plastic material and is effective in setting the colorthereof, covering the latter with a lamina of material to which theplastic material does not adhere, passing a tool over said lamina andproducing in the outer plastic cementitlous materials elevations anddepressions resembling those of undressed stone, removing thenon-adhering lamina, and

then forming in said outer plastic cementitlous materials furrows orgrooves of design and configuration substantially in alinement with theprior markings on the surface of said first layer `of cementitiousmaterial and in simulation of mortar joints on the surfaces of stonestructures. '1. In a process of making an artificial stone facing,applying to a supporting base a layer of cementitlous material inplastic form, marking` the surface of said layer into zones insimulation of individual stones in facings of natural stone, thenapplying upon -said layer colored'- cementitious material in plasticform at said zones, covering said colored cementitlous material with avlamina of material to which the plastic material does not adhere,passing a tool over said lamina and producing in the outer plasticcementitious materials elevations and depressions resembling those ofundressed stone, removing the nonadhering lamina, and then forming insaid outer plastic cementitious material furrows or grooves insimulation'of mortar joints on the surfaces of stone structures.

8. In a process of making .an articial stone facing, applying to asupporting base a layer of cementitlous material ink plastic form,marking the surface of said layer into zones in simulation of individualstones in.facings of natural stone,

then applying upon said layer other cementitlous material in plasticform and of a plurality of colors at said zones, covering said coloredcementitious material with thin waterproof paper, passing a roller witha crinkled surface over said paper and producing in the outer plasticcementitlous materials elevations and depressions reof design andconfiguration in simulation of mor' tar joints on the surfaces of stonestructures.

9. In a process of making an articial stone facing, applying to asupporting base a layer of cementitlous material in plastic form,marking the surface of said layer into zones in simulation of individualstones in facings of natural stone, then applying upon said" layercolored cementitlous material in plastic form at said zones, coveringsaid colored cementitious material with a lamina of material to whichthe plastic material does not adhere, passing a tool over said laminaand producing in the outer plastic cementitlous materials elevations anddepressions resembling those of undressed stone, forming in saidv outerplastic cementitlous material furrows or grooves in simulation of mortarjoints on the surfaces of stone structures and removing the non-adheringlamina.

10. In a process of making an artificial stone facing, applying to asupporting base a layer of f cementitious material in plastic form, thenapplying upon said layer colored cementitlous material in plastic format pre-determined zones, covering said colored cementitlous materialwith thin waterproof paper, passing a roller with a crinkled surfaceover said paper and producing in the outer plastic cementitlousmaterials elevations and depressions resembling those of undressedstone, removing the waterproof paper, and then forming in said outerplastic cementitlous materials furrows or grooves of design andconfiguration substantially in alinement with the boundaries of thepre-determined zones on the surface of said first layer of cementitlousmaterial and in simulation of mortar joints on the surfaces of stonestructures.

11. In a process vof making an artificial stone facing, applying to asupporting base a layer of cementitlous material in plastic form, thenapplying upon said layer colored cementitlous material in plastic format pre-determined zones, covering said colored cementitlous materialwith a lamina of material to which the plastic material does not adhere,passing a tool over said lamina and producing in the outer plasticcementitlous materials elevations and depressions resembling those ofundressed stone, removing the non-adhering lamina, and then forming insaid outer plastic cementitlous material furrows or grooves LEWIS ALBERTKNIGHT.

